Craftsman Airplane Wheelchair - DIY Personal Portable Aisle Chair (Wood)

Why Design and Build an Airplane Wheelchair - Personal Portable Aisle Chair?

Did you know that mobility-challenged airline passengers are usually unable to use the airplane lavatory during flights?

We did not. So we designed and have posted on Instructables two prototype wheelchairs on this topic: 1) Airplane Wheelchair - DIY Personal Portable Aisle Chair (Wood) and 2) Airplane Wheelchair - DIY Personal Portable Aisle Chair (PVC).

The Airplane Wheelchair - DIY Personal Portable Aisle Chair (PVC) posting contains more information about the philosophy behind both versions of the Personal Portable Aisle Chair. This same information is posted at the end of this Instructable in the section: Reason for the Project, Design Philosophy, and More Detailed General Description (Step 5).

The wheelchair device described here weighs less than 30 pounds. The footprint is 21.5 inches by 14 inches. The distance from the floor to the top of the seat is 17 inches. This matches the specs for airline seats and toilets.

If you are working on a similar project, let us (Meg and Doug) know because we are always interested in the work of others in the same project area.

A complete supply list and more information about each supply item is found in the section: Appendix A: Complete Supply List and More Information About Each Supply Item (Step 4).

Step 1a. and the Wood

Sand the cut end of each piece of wood with sandpaper to improve the look of the end and remove splinters.

Step 1b. Drill the Holes for the Wheel Bolts

1. Take the two (2) 21.5-inch pieces of 1X4 Red Oak and the four (4) of Caster Wheels.
2. Place a wheel in the corner of each 21.5-inch piece of 1X4 Red Oak. The base of the wheel has four holes for bolts. Mark the bolt hole position on the wood (e.g., with a pencil).
3. Use the Power Drill and a 5/16 Bit to drill four holes in the wood (one hole at each mark). Check to see if a 5/16 Hex Bolt fits in the hole. If not, adjust the hole with the Power Drill and 5/16 Bit. You want the hole to be large enough for the 5/16 Hex Bolt, but not much bigger than the Bolt.
4. Put the wheels aside.

Step 1c. Glue the H-Base Frame

1. Take the two (2) 14-inch pieces of 1X4 Red Oak and position them to form the horizontal part of an "H" with the two (2) 21.5 inch pieces as the vertical of the H. These should be placed parallel to each other and 1 inch apart in the middle of the vertical 21.5 inch pieces. The edge of each 14-inch piece is 6.75 inches from the end of the 21.5 inch piece (6.75 + 3.5 + 1 + 3.5 + 6.75 = 21.5).
2. Glue the H together - glue the two (2) horizontal parts to the two (2) vertical parts using Gorilla Glue.
3. Use a C-clamp to hold the pieces together while the glue dries. If you have four C-clamps, you can glue all four ends of the horizontal bars at the same time.
4. After the glue dries, take the two (2) 7-inch pieces of 1X4 Red Oak place one each on top of the glued 14-inch horizontal pieces between the 21.5 inch vertical pieces.
5. Glue each 7-inch piece to both the 14-inch piece and the 21.5 inch pieces using Gorilla Glue.
6. Use a C-clamp to hold the pieces together while the glue dries. If you have two C-clamps, you can glue both pieces of the horizontal bars at the same time.

Step 1d. Bolt the Rear Chair Guides and the Wheels to the Base

1. Take two (2) of the 3.5 inch pieces of 1X2 Red Oak. Position one each over the inner set of the rear wheel drilled bolt holes.
2. Clamp each 3.5 inch piece of 1X2 Red Oak to the 21.5 inch piece of 1x4 Red Oak. Use the Power Drill and a 5/16 drill bit to continue the hole in the 1X4 Red Oak through the 3.5 inch piece. If you If you have two C-clamps, you can drill both 3.5 inch pieces at the same time.
3. Check to see if a 5/16 Hex Bolt fits in the hole. If not, adjust the hole with the Power Drill and 5/16 Bit. You want the hole to be large enough for the 5/16 Hex Bolt, but not much bigger than the Bolt.
4. Bolt each wheel to the H-Base Frame. The nut for each bolt is on the same side as the wheel.
5. For the front wheels, place a 5/16 Flat Washer on a 1 Inch 5/16 Hex Bolt, insert the 5/16 Hex Bolt through the wheel base plate and through the 21.5 inch piece of wood, place another 5/16 Flat Washer on the Hex Bolt, and screw on a 5/16 Hex Nut.
6. For the back wheels, 1 Inch 5/16 Hex Bolts are used at the very back edge of the 21.5 inch 1x4 Red Oak; 2 1/2 inch 5/16 Hex Bolts are used for the other bolt holes to secure not only the wheel, but also the 3.5 inch 1X2 Red Oak rear chair guide.
7. For the holes at the very back edge, place a 5/16 Flat Washer on a 1 Inch 5/16 Hex Bolt, insert the 5/16 Hex Bolt through the wheel base plate and through the 21.5 inch piece of wood, place another 5/16 Flat Washer on the Hex Bolt, and screw on a 5/16 Hex Nut.
8. For the front set of holes for the back wheels, place a 5/16 Flat Washer on a 2 1/2 Inch 5/16 Hex Bolt, insert the 5/16 Hex Bolt through the wheel base plate and through the 21.5 inch piece of wood, place two (2) more 5/16 Flat Washers on the Hex Bolt, insert the Hex Bolt through the 3.5 inch piece of wood, place another 5/16 Flat Washer on the Hex Bolt and screw on a 5/16 Hex Nut.
9. Tighten each bolt-nut combination as much as possible using a pair of pliers and a wrench. Place Loctite Threadlocker on the exposed threads of the Hex Bolt.

Step 1e. Glue the Front Chair Guides to the Base

1. Take two (2) of the 3.5 inch pieces of 1X2 Red Oak and the two (2) 135 Degree Angle Brackets.
2. Position one (1) 135 Degree Angle Bracket on each 21.5 Inch Red Oak 5 inches from the front of the edge of the Base and 1/4 inch from the inner side of the Red Oak (side adjoining the 7 inch piece of Red Oak).
3. Mark the position of the hole in the Angle Bracket on the wood. Use the Power Drill and a 1/4 Bit to drill a hole in the wood. Check to see if a 1/4Inch Hex Bolt fits in the hole. If not, adjust the hole with the Power Drill and 1/4 Bit. You want the hole to be large enough for the 1/4 Hex Bolt, but not much bigger than the Bolt.
4. Place J-B Weld on the bottom of each Angle Bracket and put back into position.
5. Place a 1/4 Flat Washer on a 1 1/2 Inch 1/4 Hex Bolt, insert the 1/4 Hex Bolt through the 21.5 inch piece of wood and through the Angle Bracket, place another 1/4 Flat Washer on the Hex Bolt, and screw on a 1/4 Hex Nut. This secures the Bracket while the J-B Weld is drying. Make sure the Bracket edge remains parallel to the Red Oak edge while drying. Do not take the Bolt out after the J-B Weld is dry.
6. Take the two 3.5 inch pieces of 1X2 Red Oak and position them 1/2 inch from the outside edge of the 1x4 Red Oak and 7.5 inches from the front of the edge of the Base.
7. Glue each 3.5 inch piece to the 1x4 Red Oak with J-B Weld. Make sure the edge of the 3.5 inch piece remains parallel to the Red Oak edge while drying.

Step 1f. Attach the Footrest

1. Take two (2) 5.5 Inch Pieces of 1x4 Red Oak and glue a 3.5 inch piece of 3/4 x 3/4 Square Wood Dowel to each end using Gorilla Glue.
2. When the glue has dried use the Power Drill and a 1/4 Bit to drill two holes in the end of each now 7 inches long (0.75 + 5.5 + 0.75 = 7) Footrest block of wood directly opposite each other.
3. Glue a 1.25 inch of 1/4 Zinc-Plated Round Rod into one side (one 7 inch Footrest block) using J-B Weld.
4. Attach a 7-inch piece of drawer slide in the middle of each 7-inch Footrest block of wood using Gorilla Glue
5. Attach a 3.5-inch piece of the drawer slide track between the wheel bolts on the 21.5 inch pieces of 1x4 Red Oak using Gorilla glue.
6. The two (2) 7 inch pieces of Footrest block should now slide back and forth and form one solid footrest when joined together.
7. If the Footrest is too wobbly, put a piece of canvas on the track to reduce the wobble.

Step 1g. Insert Dowels for Added Strength and Charm

1. Use the Power Drill and a 1/4 Bit to drill holes in the Base wherever a dowel would improve strength and charm.
2. Drill a hole completely through the wood.
3. Take a piece of 1/4 Inch Raw Wood Round Dowel of the right length to go completely through the wood and glue it into each hole using Gorilla Glue.

Step 2a. Assemble the Seat

1. Take two (2) 14-inch pieces of 1x2 Red Oak and glue them together along their 1.5 inch faces. Repeat with another set of two (2) 14-inch pieces.
2. Use a C-clamp to hold the pieces together while the glue dries. If you have two C-clamps, you can glue both pieces at the same time.
3. When the glue dries use the Power Drill and a 1/4 Bit to drill a hole in the middle of the non-glued side completely through the glued wood. This hole should be 8 inches from the top. Check to see if a 1/4 Hex Bolt fits in the hole. If not, adjust the hole with the Power Drill and 1/4 Bit. You want the hole to be large enough for the 1/4 Hex Bolt, but not much bigger than the Bolt.
4. Take two (2) 17-inch pieces of 1x2 Red Oak and glue them together along their 1.5 inch faces. Repeat with another set of two (2) 17-inch pieces.
5. Use a C-clamp to hold the pieces together while the glue dries. If you have two C-clamps, you can glue both pieces at the same time.
6. When the glue dries use the Power Drill and a 1/4 Bit to drill a hole in the middle of the non-glued side completely through the glued wood. This hole should be 10.5 inches from the top. Check to see if a 1/4 Hex Bolt fits in the hole. If not, adjust the hole with the Power Drill and 1/4 Bit. You want the hole to be large enough for the 1/4 Hex Bolt, but not much bigger than the Bolt.
7. Glue using J-B Weld a 14-inch piece of 1x2 Red Oak to the top of each the 14-inch glued wood. Make sure the two pieces of 14-inch wood remain parallel and 10 1/4 inches apart.
8. Glue using J-B Weld a 14-inch piece of 1x2 Red Oak and to the top of the 17-inch glued wood. Make sure the two pieces of 17-inch wood remain parallel and 6 7/8 inches apart.
9. Join the 14-inch and 17-inch parts together with a bolt on each side with the nut out the outside.
10. For each side, place a 1/4 Flat Washer on a 4 1/2 Inch 1/4 Hex Bolt, insert the 1/4 Hex Bolt through the 14-inch part, place two (2) more 1/14 Flat Washers on the Hex Bolt, insert the Hex Bolt through the 17-inch piece of wood, place another 1/4 Flat Washer on the Hex Bolt and screw on a 1/4 Hex Nut.
11. Do not tighten the bolt-nut assembly too much. This unit is intended to swivel. However, do use Loctite on the exposed threads.
12. Place the bolted pieces on the base with the longer legs (17-inch) in the front against the Angle Bracket. Cut the feet at an angle so they lie flat on the base. A Miter Box and Saw works well to make these cuts.

Step 2b. Assemble the Back

1. Take the two (2) 18-inch pieces of 1x2 Red Oak and glue a 14 inch piece of 1x2 Red Oak across the top of each with Gorilla Glue making sure that the 18-inch pieces remain parallel 10 inches apart and centered on the 14-inch piece.
2. Glue - using Gorilla Glue - a 10 inch piece of 1x2 Red Oak to the inner side of each 18-inch piece with the 10 inch piece also glued to the 14-inch piece.
3. When the glue is dry, glue another 10 inch piece to the bottom of each of the vertical 10 inch pieces.
4. Glue - using Gorilla Glue - a 3.5 inch piece at the intersection of the 18-inch piece and the 14-inch piece to form handles.
5. Place a 1/4 Inch Rod End Protector, Plastic on each of the four (4) 3.25 inch 1/4 Zinc-Plated Round Rods.
6. Use the Power Drill and a 1/4 Bit to drill a hole in the middle of each 18-inch piece of 1x2 Red Oak 1.5 inches from the bottom. Check to see if a 1/4 Inch Round Rod fits in the hole. If not, adjust the hole with the Power Drill and 1/4 Bit. You want the hole to be large enough for the 1/4 Inch Round Rod, but not much bigger than the Rod.
7. Using the Power Drill, continue the Round Rod holes through the 17-inch Chair Seat legs. Push the Round Rod through the hole to attach the Back to the Chair.
8. To stabilize the Back and keep it from tipping, Install a 3/4-Inch Corner Brace on each 18-inch piece of wood using J-B Weld and machine screws. Also install the two (2) 6-inch pieces of 1x2 Red Oak on the Back at an angle to prevent tipping and secure with the removable Round Rods and a Corner Brace secured to the 14-inch top of the rear of the Chair Seat.

Step 2c. Insert Dowels for Added Strength and Charm

1. Use the Power Drill and a 1/4 Bit to drill holes in the Chair wherever a dowel would improve strength and charm.
2. Drill a hole completely through the wood.
3. Take a piece of 1/4 Inch Raw Wood Round Dowel of the right length to go completely through the wood and glue it into each hole using Gorilla Glue.

Step 3a. Stain and Polyurethane the Wood

1. Stain the Square Dowel parts of the Footrest with a Dark Walnut Stain.
2. Take the Wood Polyurethane and Applicator Brush and/or Cloth and polyurethane the wood. You can polyurethane the wood when it is in pieces before the assembly. However, make sure you do not polyurethane the places you will glue. The glue sticks better to raw wood.

Step 3b. Create the Canvas Chair Seat and Back "Cushions"

1. Take the one (1) 40 Inch by 40 Inch Piece of Green Duck Canvas and the one (1) 27 Inch by 40 Inch Piece of Green Duck Canvas and Iron-On Stitch Witchery. The shorter piece will wrap around the back of the chair to form the back "cushion". The longer piece will wrap around the seat of the chair to form the seat "cushion".
2. Fold each piece over to double it. We doubled it by creating a back seam in the middle - five (5) inches folded over each side.
3. Use the Iron-On Stitch Witchery to secure the two 5-inch back pieces to the front 10-inch piece.
4. Fold over the top of each of the two pieces and install the grommet/eyelets. Three (3) grommet/eyelets evenly spaced on each side of the chair back canvas. Five (5) grommets/eyelets evenly spaced on each side of the chair seat canvas. You can put glue on and around the grommets/eyelets to strengthen them.
5. Place a 10-inch piece of 1/4 Inch Round Wood Dowel in the loop fold at the top of the pieces (4 10-inch dowels).
6. Take the Iron-On Denim and iron it to the entire back of each canvas piece to strengthen it.
7. Take the Chair Back canvas and wrap it around the Chair Back. Overlap the grommets/eyelets and secure them with the #10 1/2 Inch Machine Screws. Place a #10 washer over the machine screw, put the machine screw into both grommets/eyelets, place another #10 washer over the machine screw, and secure with a #10 nut. Tighten as much as possible. You can secure these with glue or Loctite.
8. Repeat this process (Step 7) with the Chair Seat canvas.

Step 3c. Create and Install the Seatbelt

1. Take the 2 Inch Heavyweight Polypropylene Webbing Seatbelt and a 2 Inch Wide Adjustable Quick Side Release Buckles. Create one 5-foot seatbelts by attaching the buckle to the ends of the 5-foot piece of webbing.
2. Install (keep the seatbelt in place) the seatbelt by winding it through the back of the back canvas cushion.

Step 3d. Install Decorative Accents
Install any decorative accents you want. We used wooden plugs to cover the visible hole in the Angle Bracket, a cloth decal on the seat, and pillows with a hummingbird cover.

Step 3e. Pack Up the Wheelchair for Travel

You can use any carrying bag you choose. We chose to use one (2) 55-liter 24” x 12” x 11.5" duffle bag for the Chair, Round Rod bolts, and the pillows. We chose not to put the Base in a bag. Each should fit in an airplane overhead bin.

Construction Materials - Wood

• 1X4 Red Oak (total: 96 inches)
• 1X2 Red Oak (total: 265 inches)
• 1/4 Inch Raw Wood Round Dowel (total: 52 inches)
• 3/4 Inch x 3/4 Inch Square Wood Dowel (total: 14 inches)

Construction Materials - Fasteners and Glue

• 1 Inch 5/16 Hex Bolts (total: 12)
• 2 1/2 Inch 5/16 Hex Bolts (total: 4)
• 5/16 Hex Nuts (total: 16)
• 5/16 Flat Washers (total: 40)
• 1 1/2 Inch 1/4 Hex Bolts (total: 2)
• 4 1/2 Inch 1/4 Hex Bolts (total: 2)
• 1/4 Hex Nuts (total: 4)
• 1/4 Flat Washers (total: 10)
• #10-32 1 Inch Round Head Machine Screws (total: 4)
• #10-32 1/2 Inch Round Head Machine Screws (total: 8)
• #10-32 Machine Screw Nuts (total: 12)
• #10 Machine Screw Washers (total: 24)
• 1/4 Zinc-Plated Round Rod (total: 15.5 inches)
• 1/4 Inch Rod End Protectors, Plastic (total: 4)
• 1/4 Inch Grommets/Eyelets (total: 16)
• Original Gorilla Glue
• J-B Weld
• Loctite Threadlocker

Construction Materials - Assorted

• Caster Wheels with Brakes (total: 4)
• Green Duck Canvas (total: 67 inches by 40 inches)
• Iron-On Stitch Witchery
• Iron-On Denim (total: 59 inches by 10 inches)
• 2 Inch Heavyweight Polypropylene Webbing Seatbelt (total: 5 feet)
• 2 Inch Wide Adjustable Quick Side Release Buckles (total: 1)
• 3/4 Inch Corner Brace (total: 4)
• 135 Degree Angle Bracket (total: 2)
• Two (2) 7 Inch Wooden Drawer Slide Pieces (total: 14 inches)

Paint and Stain

• Dark Walnut Wood Stain
• Wood Polyurethane
• Applicator Brush and/or Cloth

Tools

• Miter Box and Saw
• Power Drill with 1/4 Inch Bit and a 5/16 Inch Bit
• 3 Inch C-Clamp
• Hacksaw
• Iron and Ironing Board
• General Use Tools You Probably Already Have: Tape Measure, Ruler, Pencil, Pliers, Wrench, Screwdriver, Scissors

Miscellaneous

• Sandpaper
• Carrying Bag
• Decorative Accents (e.g., Pillows)

Red Oak Lumber: 1X4 Red Oak - Two (2) 21.5 Inch Pieces, Two (2) 5.5 Inch Pieces, Two (2) 7 Inch Pieces, Two (2) 14 Inch Pieces (total: 96 inches) and 1X2 Red Oak - Six (6) 3.5 Inch Pieces, Two (2) 6 Inch Pieces, Seven (7) 14 Inch Pieces, Four (4) 17 Inch Pieces, Two (2) 18 Inch Pieces, Three (3) 10 Inch Pieces (total: 265 inches) and Miter Box and Saw

Note: 1X4 lumber is really 0.75 inches by 3.50 inches and 1X4 lumber is really 0.75 inches by 1.50 inches. This lumber can be purchased at almost any store selling lumber. For example, Home Depot 1X4 Red Oak and Home Depot 1X2 Red Oak. This lumber is often sold by the foot - you can buy only what you need. And some places, like Home Depot, may cut the wood for you - with certain restrictions (e.g., will not cut a piece shorter than 12 inches). If you are cutting the wood yourself, a Miter Box and Saw are helpful (although you can use any saw you have). The Miter Box and Saw can be purchased at almost any hardware store. Home Depot, for example Stanley 14.5 in. Deluxe Clamping Miter Box with 14 in. Saw.

Wood Dowels: 1/4 Inch Raw Wood Round Dowel - Four (4) 10 Inch Pieces, Twelve (12) 1 Inch Pieces (total: 52 inches) and 3/4 Inch x 3/4 Inch Square Wood Dowel - Four (3.5) Inch Pieces (total: 14 inches)

These dowels can be purchased at almost any hardware store or garden store. For example, for the round dowel, Home Depot 1/4 in. x 48 in. Raw Wood Round Dowel. The dowel is usually sold in only one length. For example, for the square dowel, Home Depot 3/4 in. x 3/4 in. x 36 in. Basswood Square Dowel. The dowel is usually sold in only one length. To cut the wood, you can use any saw you have or the Miter Box and Saw. A knife also works as well with the 1/4/ Inch Raw Wood Round Dowel.

Bolts, Nuts, and Washers: 1 Inch 5/16 Hex Bolts (total: 12), 2 1/2 Inch 5/16 Hex Bolts (total: 4), 5/16 Hex Nuts (total: 16), 5/16 Flat Washers (total: 40) and 1 1/2 Inch 1/4 Hex Bolts (total: 2), 4 1/2 Inch 1/4 Hex Bolts (total: 2), 1/4 Hex Nuts (total: 4), 1/4 Flat Washers (total: 10) and Four (4) 3.25 inch 1/4 Zinc-Plated Round Rods, Two (2) 1.25 inch 1/4 Zinc-Plated Round Rods (total: 15.5 inches), 1/4 Inch Rod End Protectors, Plastic (total: 4)

These items can be purchased at almost any hardware store. For example, Home Depot 5/16 in.-18 tpi x 1 in. Zinc-Plated Hex Bolt and 5/16 in.-18 x 2-1/2 in. Zinc Plated Hex Bolt and 5/16 in.-18 Zinc Plated Hex Nut and 5/16 in. Zinc Flat Washer and 1 1/2 Inch 1/4 Hex Bolts and 4 1/2 Inch 1/4 Hex Bolts and 1/4 Hex Nuts and 1/4 Flat Washers and 1/4 zinc-plated round rod and 1/4 in. White Rubber Thread Protectors (2-Piece). We used a hacksaw to cut the Round Rod into the sizes needed.

Machine Screws and Grommets: #10-32 1 Inch Round Head Machine Screws (total: 4), #10-32 1/2 Inch Round Head Machine Screws (total: 8) #10-32 Machine Screw Nuts (total: 12), #10 Machine Screw Washers (total: 24) and 1/4 Inch Grommets/Eyelets (total: 16)

These items can be purchased at almost any hardware store. For example, Home Depot #10-32 x 1 in. Combo Round Head Zinc Plated Machine Screw (6-Pack) and #10-32 x 1/2 in. Combo Round Head Zinc Plated Machine Screw (8-Pack) and #10 Zinc Flat Washer (30-Pack). Grommets (sometimes called eyelets) can be purchased in many locations (e.g., hardware stores). The ones we used were brass-colored ones made by Dritz - 1/4″ Large Eyelets & Tool. We used a standard hand-held paper punch to punch the holes and then used a vice-grip in combination with the tools provided in the Dritz product to install the grommets/eyelets.

Original Gorilla Glue, J-B Weld, Loctite Threadlocker, Dark Walnut Wood Stain, Wood Polyurethane, Applicator Brush and/or Cloth, Sandpaper, Power Drill with 1/4 Inch Bit and a 5/16 Inch Bit, and 3 Inch C-Clamp

These items can be purchased at almost any hardware store. For example, Home Depot Original Gorilla Glue and J-B Weld Two 1 oz. Twin Tube Kwikweld and Loctite Threadlocker Blue 242 and Varathane Dark Walnut Classic Wood Interior Stain and Varathane Clear Gloss Oil-Based Interior Polyurethane and Angled Artist Paint Brush Set and SuperiorBilt Cheesecloth Cotton Pack and Assorted Grit Medium, Fine and Very Fine Garnet Sandpaper and Black & Decker 20-Volt MAX Lithium-Ion Cordless 3/8 in. Drill/Driver with Battery 1.5Ah and Charger and Husky 3 in. C-Clamp. For the drill bits, Amazon is a good source. For example, Black & Decker Screwdriver Bit Set/Drill Bit Set, 109-Piece (BDA91109).

Caster Wheels with Brakes (total: 4)
Caster wheels can be purchased from a number of vendors. The ones used in this project were purchased from the Abslimus store via Amazon and are 4 inch Heavy Duty Casters, Lockable Bearing Caster Wheels with Brake, Swivel Casters for Furniture and Workbench, Set of 4, Load 1800lbs (Free screws and a spanner). The ones purchased for this project are now listed as Currently Unavailable (8/9/21) on Amazon, but they may be available from another vendor - or they may become available on Amazon again in the future.

One (1) 40 Inch by 40 Inch Piece of Green Duck Canvas (Doubled Over) and One (1) 27 Inch by 40 Inch Piece of Green Duck Canvas (total: 67 inches by 40 inches), Iron-On Stitch Witchery, Iron-On Denim (total: 59 inches by 10 inches), 2 Inch Heavyweight Polypropylene Webbing Seatbelt (total: 5 feet), and 2 Inch Wide Adjustable Quick Side Release Buckles (total: 1)

The Duck Canvas, Iron-On Stitch Witchery, and Iron-On Denim are available at many fabric stores and online. For example, Joann's Fabrics Duck Canvas Fabric and Amazon for Dritz 222 STITCH WITCHERY FUSIBLE BONDING WEB WHITE REG WGHT 20YD, 5/8-Inch X 20-Yards and Azobur Iron on Patches for Clothing Repair, Jean Patches for Inside and Outside, Sew on Iron on Denim Patches for Jeans Kits 4"x 60"(10.5cm x 152.5cm) (Dark Blue No. 1). The polypropylene webbing and the buckles may be available from local vendors, but are available online. For example, Amazon Strapworks Heavyweight Polypropylene Webbing - Heavy Duty Poly Strapping for Outdoor DIY Gear Repair, 2 Inch x 10 Yards - Khaki and SGH Pro Extra Thick Hard Plastic Materials Military Grade Dual Adjustable Quick Side Release Buckles 2 Inch Wide 4 Pack Clips Snaps No Sewing Replacement for Nylon Strap Webbing Boat Cover Backpack.

3/4 Inch Corner Brace (total: 4), 135 Degree Angle Bracket (total: 2), Two (2) 7 Inch Wooden Drawer Slide Pieces (total: 7 inches)

The 3/4 Inch Corner Brace can be purchased at almost any hardware store. For example, Home Depot Everbilt 3/4 in. Zinc Plated Corner Braces (4-Pack) are available online. For the 135 Degree Angle Bracket and the Wooden Drawer Slide, Amazon is a good source. For example, luluxing 135 Degree 3030 Aluminum Profile Angle Bracket Accessories Pack of 5 (135 Degree) and Btibpse Wooden Drawer Slides 40cm Classic Wood Center Guide Track (15-3/4'')

Carrying Bag and Decorative Accents

There are many options for both the type of carrying bag and from where it can be purchased. One option is online. For example, Amazon 55 Liter, 24 Inch Lightweight Canvas Duffle Bags for Men & Women For Traveling, the Gym, and as Sports Equipment Bag/Organizer (Black 2). There are also many options for the type of decorative accent and from where it can be purchased. We used options offered by Amazon Yggdrasil The Tree of Life in Norse Patch Embroidered Badge Iron On Sew On Emblem and Nine City Geometric Hummingbird Abstract Colour, Square Pillow Throw Case Sofa Bed Home Pack of 2 12x12 Inches as well as Home Depot General Tools 3/8 in. Flat Head Plugs.

Why Design and Build an Airplane Wheelchair - Personal Portable Aisle Chair?

Did you know that mobility-challenged airline passengers are usually unable to use the airplane lavatory during flights?

We did not. A mobility-challenged friend recently told us about the hardship. Many mobility-challenged airline travelers arrange short-duration-multi-stop flights and restrict pre-flight and during travel fluid intake to be able to "hold it" between airport-located lavatories. We have been told that severe dehydration sometimes results from such airline travel. Wheelchair Travel discusses some of these air travel issues at Wheelchair Accessible Lavatories.

To use the airplane lavatory, a mobility-challenged passenger needs a wheelchair which can move in the small airplane aisle (often 15" wide) to the lavatory door, can be maneuvered into and within any airplane lavatory, and allows the passenger to transfer to-and-from the airplane seat as well as to-and-from the airplane toilet. Such a wheelchair is not always available in-flight for a mobility-challenged passenger.

Airlines usually use an airplane aisle wheelchair (often called an aisle chair) to move mobility-challenged passengers on and off the airplane. However, that aisle chair is often left at the airport and is not available in-flight. Many aisle chairs do not seem to fit a standard airplane lavatory. When an aisle chair is on-board, it is under the control of the crew and not the passenger.

We were horrified by this situation and decided to design and build a DIY airplane wheelchair - a personal portable aisle chair - with relatively inexpensive materials which can be found in most any hardware store, tools which even a beginner builder can successfully use, and which can be built/assembled in a residential space (e.g., a living room, a balcony).

We have posted two prototype chairs on this topic on Instructables: 1) Airplane Wheelchair - DIY Personal Portable Aisle Chair (Wood) and 2) Airplane Wheelchair - DIY Personal Portable Aisle Chair (PVC).

If you are working on a similar project, let us (Meg and Doug) know because we are always interested in the work of others in the same project area.

Design Philosophy (General Functional Specifications)

Some of the sources of information were:

• Carry-On Luggage Size Chart for 58 Major Airlines [Dimensions, Sizes & More]
• Anthropometric Study to Update Minimum Aircraft Seating Standards
• How to Lift the Aisle Armrest on an Airplane
• United States Department of Transportation, Wheelchairs and Other Assistive Devices – Airplane Wheelchair

The development philosophy behind the project is that a device is needed which can be used in the aircraft aisle, used to access the lavatory, and can be stored in the cabin of the aircraft. The best design is one which is easily portable and completely under the passenger’s control – no need for the cabin crew. The assumption is that the passenger requiring the wheelchair is accompanied by a traveling companion on the plane - a traveling companion who can push the wheelchair in the airplane aisle to and from the lavatory and then into the lavatory. Additionally,

----- The wheelchair device must be one which can be dissembled and placed in a luggage bag which can be stored either in an airplane overhead bin or a combination of the overhead bin and under the airplane seat.

----- The wheelchair device must be one which can be easily and quickly taken from the overhead and under the seat and assembled for use by the traveling companion while in flight and then disassembled and replaced in the overhead and under the seat by the traveling companion while in flight.

----- The wheelchair device must be one that a traveling companion can easily move in the airplane aisle and into the lavatory.

General Description of the Finished Airplane Wheelchair - DIY Personal Portable Aisle Chair (Wood)

The overall look of the airplane wheelchair device is “steampunk-meets-director's-chair” – decidedly non-medicinal. There are two major components of the wheelchair - a base and a chair. Each is made from wood. The chair seat and back rest "cushions" are made from canvas and the chair has one seatbelt.

Caster wheels on the bottom of the base allow movement left/right and back/forth and each wheel has an independent push-down braking mechanism. The wheels are rated at 1800 pounds; full ball bearing, very smooth.

The wheelchair device described here weighs less than 30 pounds. The footprint is 21.5 inches by 14 inches. The distance from the floor to the top of the seat is 17 inches. This matches the specs for airline seats and toilets.